ACO DIGISYS Operating Instructions Manual Download Page 1

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ACO – DMMS - DIGISYS

Moisture Measuring System

Operating Instructions

2020 en

ACO A

utomation

mponents Johannes Mergl e.K. * Industriestr. 2 * D-79793 Wutoeschingen-Horheim

Tel.: +49 (0)7746 91316 * Fax.: +49 (0)7746 91317 * Email:

[email protected]

* www.acoweb.de

Summary of Contents for DIGISYS

Page 1: ...oisture Measuring System Operating Instructions 2020 en ACO Automation Components Johannes Mergl e K Industriestr 2 D 79793 Wutoeschingen Horheim Tel 49 0 7746 91316 Fax 49 0 7746 91317 Email info acoweb de www acoweb de ...

Page 2: ... cable with separate cable con duits Heavy electromagnetic impacts could interfere the communication between sen sors an evaluation unit Do not exit the calibration software in the screen windows Test Image or Take Sample Please disconnect the communication between calibration software and evaluation unit first after activate one of the following screenwindows Configuration Curves Info or Moisture...

Page 3: ...rvision 9 2 4 3 Operation and maintenance 9 2 4 4 Assembly and repair 9 3 TECHNICAL DATA 10 3 1 DMMS Sensor 10 3 2 Bus connection socket 12 3 3 Evaluation and transmission module 13 3 4 Power pack DIN rail mounting 14 3 5 PROFIBUS DP measuring value transmission 15 3 6 PC software 16 4 SYSTEM SUMMARY 17 5 DMMS MOISTURE SENSOR 18 5 1 Short description of sensor 18 5 2 Safe operation 19 5 3 Install ...

Page 4: ...8 3 1 Window 36 8 3 2 Symbol list 36 8 3 3 Menu structure 37 8 4 Extras Settings 38 8 4 1 Menu connect 39 8 4 2 Menu write 39 8 5 Moisture screen temperature screen 40 8 6 Info 41 8 7 Service 42 8 7 1 Configuration 42 8 7 2 Test screen 47 8 7 3 Take sample 48 8 7 4 Curves 50 8 8 System 54 8 8 1 Settings 54 8 8 2 External material switching through digital inputs 55 8 8 3 Example configuration 57 8...

Page 5: ...mponents Operating Instructions DMMS_DIGISYS 5 Foreword 12 CONNECT THE USB ADAPTER 64 12 1 1 Install the driver software 64 12 1 2 Connect the USB adapter 68 12 1 3 Switch out the USB adapter 70 12 1 4 Technical data 70 ...

Page 6: ...ndly submitted by them Registered trademarks MS WINDOWS 95 98 ME NT4 2000 XP MS EXCEL are registered trademarks of the Microsoft Corpo ration PROFIBUS is a registered trademark of the PROFIBUS User Organisation PNO Copyright and company address Copyright 2009 ACO AUTOMATION COMPONENTS Johannes Mergl e K Industriestrasse 2 79793 Wutöschingen Horheim Germany Document identification Compiled by ACO A...

Page 7: ...measuring system according to the operating instructions and as directed i e conscientious of safety and dangers which may occur and only if it can be guaranteed that the system is in a technically sound condition In particular faults which may impede safety must be remedied immediately Any other use as well as exaggerated use is not considered use as directed The manufacturer or supplier will not...

Page 8: ... consequence WARNING WARNING indicates a dangerous situation If the warning is not heeded death or serious bodily injury may be the consequence CAUTION CAUTION indicates a dangerous situation If the warning is not heeded serious bodily injury may be the consequence CAUTION CAUTION indicates a dangerous situation If the warning is not heeded serious property damage may be the consequence Further in...

Page 9: ...racted personnel are actively involved with the measuring system Employ trained or instructed personnel only Explain responsibilities regarding operation maintenance and repair clearly to all personnel Ensure that the legally required minimum age is observed Before commencing work inform all operating personnel of repair tasks which may be required Nominate supervisors Only allow repair tasks to b...

Page 10: ...iprocessor protocol Max number of sensors at the bus 16 Maximum bus length 1200 m Microprocessor AT89C51ED2 Power supply 8 30V 0 4 VA Measuring range temperature measurement 10 C 90 C Measuring precision temperature measu rement 0 5 C Operational ambient temperature 5 C 72 C Operating temperature electronic 20 C 80 C Storage temperature 25 C 80 C Type of protection IP68 Connection line type UNITRO...

Page 11: ...ACO Automation Components Operating Instructions DMMS_DIGISYS 11 Technical data Measurement gauge Master gauge for holes 60 mm var Ø76 70 76 ...

Page 12: ...hawing 95 Identification of conformity CE Vibration resistance in accordance with IEC 60068 2 6 Shock resistance in accordance with IEC 60068 2 27 Type of protection IP 66 EMC interference immunity in accordance with EN 50082 2 96 EMC interference emission in accordance with EN 50081 2 94 Cable ports 4 x Pg 11 or M16 stainless steel Screen clamps 4 x CAGE CLAMP 2 5 mm Bus terminals 18 x CAGE CLAMP...

Page 13: ...channel analogue output terminal 0 10 V WAGO 750 402 4 channel digital input terminal 3ms WAGO 750 513 Relay output terminal 250V AC 30V DC 2A AC DC WAGO 750 504 4 channel digital output terminal WAGO 750 653 000 020 Serial interface RS485 WAGO 750 554 2 channel analogue output terminal 4 20mA WAGO 750 600 End terminal Moxa NPort 5110 EU Ethernet RS 232 Adapter http www moxa com WAGO 750 920 Commu...

Page 14: ...d conditions Power reduction 3 K from 50 C Mains buffering 20 ms with Ue 187 VAC Internal fuse 2 0 A flink Output Nominal voltage tolerance 2 1 at 5V 3 Residual ripple 100 mVss Interference voltage 150 mVss Temperature coefficient 0 025 K Enabling characteristics disabling characteristics No overshooting of Ua soft start Enabling delay 0 8 s Starting time 30 ms Overvoltage protection 130 from Ua n...

Page 15: ... EN50170 Bus segment length 100 1200m Transmission rate 9600 12M bit s Bus connection 9 pin Sub D male Protocol DP DPVI GSD file WAGOB756 GSD download www wago com Measuring channels 1 16 1 input data measuring channel s n 2 2 byte 2 output data measuring channel s n 6 4 byte 1 This regards output variables where the PROFIBUS Master is concerned 2 This regards input variables where the PROFIBUS Ma...

Page 16: ...lue representation 1 of 16 Parameterisation 1 of 16 Calibration 1 of 16 Switching of material curves yes Service and diagnosis yes Software system prerequisite Operating systems Microsoft Windows WIN 95 98 ME NT4 0 2000 XP Vista Documentation Acrobat Reader Hardware system prerequisite CPU Pentium min133MHz RAM memory 32MB Fixed disk storage free 10MB Installation drive CD ROM Interface RS232B or ...

Page 17: ...titude of interfaces can be realised for the overriding systems An easy to use PC software allows a quick and precise calibration of the measuring sections Sensorbus Bus length max 1200m Bus connection outlet for 1 2 sensors 1 16 DMMS sensors on the bus PROFIBUS DP Measure value transfer material curve switching DIGISYS module modularly extendable Power pack 24V DC PC Software DMMS DIGISYS Display...

Page 18: ...ture measuring Temperature compensation Material specific adjustment Digital interface networking Error report A precise calibration at the factory allows complete reproducibility over a wide temperature range Thus the material specific calibration can be assigned to other measurement sections No new calibration is necessary when the sensor is replaced The sensor receives a measuring task from the...

Page 19: ...voltage Fatalities as a result of electric shocks Switch off the system and secure against restarting Inform all persons within immediate proximity of the system Procedure for switching off and securing the system observe the system operating instructions Whenever switching on the plant WARNING Drives can start up automatically Body parts and clothing can be drawn into machinery Warn all persons w...

Page 20: ...flush with the wallpartition Tighten the straining screw E first and then the fastening B Clamp the sensor cable to the bus connection socket and tighten the cable gland Assembly a Countersink screw B Washer c Spring washer d Nut A Cladding B Fastening C Wheel flange D Sensor E Tensioning screw Master gauge R38 1 CAUTION Observe the following instructions for handling sensors otherwise the sensor ...

Page 21: ...r 50mm ispresent The moisture measuring value must be verified through a laboratorytest A sufficient quantity of material representative of the mix is extracted and at the same time the moisture measuring value or the fraction value is recorded If the deviations are too large the calibration curves can be adjusted see PC software or display and parameteringmodule 5 5 Replacing the sensor 1 Switch ...

Page 22: ...tion socket The ACO bus connection socket facilitates installation of the sensor bus Protection type IP66 Connection of 1 or 2 moisture sensors Connection of 1 or 2 bus lines Bus termination Allocation of sensor address Fine protection against lightning CAGE CLAMP connection technology 4 cable clamps ...

Page 23: ...through the holes B 2 1 2 Connect the sensors the white and grey wires serve to determine the sensor address 3 Connect the cable from the sensor bus For the last connection socket set a resistance with 120 ohms between clamps A and B 4 Connect the shielded braid from the cable on the shielded clamps 5 Tighten the cable fittings 6 Mount the connection socket cover ...

Page 24: ...bn rs ge gn ws gr 2 bn rs ge gn ws gr 3 bn rs ge gn ws gr 4 bn rs ge gn ws gr 5 bn rs ge gn ws gr 6 bn rs ge gn ws o o gr 7 bn rs ge gn ws gr 8 bn rs ge gn ws gr 9 bn rs ge gn ws gr 10 bn rs ge gn ws o o gr 11 bn rs ge gn ws o o gr 12 bn rs ge gn ws o o gr 13 bn rs ge gn ws gr 14 bn rs ge gn ws o o gr 15 bn rs ge gn ws gr 16 bn rs ge gn ws gr Do not set any double sensor addresses Sensor cable len...

Page 25: ...rders Storage of measuring section configuration curves thresholds etc Summarization of measured values from several sensors Switching of material curves Error report 7 1 Measuring operation Moisture measuring is initiated automatically following activation of the DIGISYS No operation is necessary in this operating mode This operation is not discontinued even within the service functions thus the ...

Page 26: ...cessing RUN From the upper to the middle position Stop program processing STOP Lower position Not required for users Press down i e using a screwdriver Hardware Reset All outputs and flags are reset Variables are set to 0 or to FALSE or to an initial value The Hardware Reset can be initiated with STOP as well as with RUN in each position of the operation mode switch A change in operation mode occu...

Page 27: ...ago com All documentation regarding the PROFIBUS is available on the PROFIBUS user organisation internet page www PROFIBUS com 7 4 LED signalisation LED Colour Explanation A B C D green Operating voltage available RUN green The field bus was efficiently initialised BF flashing red Communication via the PROFIBUS is not func tioning DIA red An external diagnosis is being performed BUS flashing code ...

Page 28: ...ensor S Adr not used however found Check addressing register sensor 3 3 Sensor channel S Adr data transfer error Cabling check power supply 3 4 Sensor channel S Adr no answer 3 5 Sensor channel S Adr incorrect answer 3 6 Sensor channel S Adr error report 3 1 1 1 Sensor S Adr found twice Cabling check addressing 7 6 1 1 WAGO RS 485 module unavailable Install WAGO I O module or remove module from th...

Page 29: ...rted in a determined sequence on a carrier rail 35x7 5 mm Amount WAGO Module type 1 750 833 Field bus controller PROFIBUS DP V1 with ACO LMT software 0 to 4 750 402 4 channel digital input terminal 3ms 0 to 4 750 504 4 channel digital output terminal 0 to 8 750 554 750 550 2 channel analogue output terminal 4 20mA or 2 channel analogue output terminal 0 10 V 0 to 8 750 513 Relay output terminal 25...

Page 30: ...faces 4 connection power pack 24V DC 5 terminating resistor 120 ohm 6 bus cable sensor bus power supply sensors A B data signal shield with output 2 x 4 20mA A controller PROFIBUS DP D output terminal 4 20mA G RS485 interface H end terminal J terminal block 1 cable 4 20mA channel 1 2 cable 4 20mA channel 2 3 configuration interfaces 4 connection power pack 24V DC 5 terminating resistor 120 ohm 6 b...

Page 31: ...on interfaces 4 connection power pack 24V DC 5 terminating resistor 120 ohm 6 bus cable sensor bus 7 connection contact 1 8 connection contact 2 shield 4 x output 0 10V 4 x start input 1x fine input A controller PROFIBUS DP B input terminals E analogue output terminals G RS485 interface H end terminal J terminal block 1 control cable start and fine signal 3 configuration interfaces 4 connection po...

Page 32: ... is connected with the communication cable B to serial inter face C of a PC notebook If the PC does not have a serial interface use the adapter USB RS232 serial adapter Refer to the operating instructions of the manufacturer 8 1 Functionality Use the USB adapter if necessary Measured value display 16 channels Configuration of the measuring channels Calibrating device Measured value simulation Mate...

Page 33: ...ctions DMMS_DIGISYS 33 PC software DMMS DIGISYS 8 2 Installation Start the English language version installation program setupXXX exe on the CD ROM Set up has been initiated click next Select I accept the agreement Select target drive directory ...

Page 34: ...Instructions DMMS_DIGISYS ACO Automation Components 34 PC software DMMS DIGISYS Select entry in the start menu Optional quick start links Details correct Click on install The software is then installed on the PC ...

Page 35: ...S_DIGISYS 35 PC software DMMS DIGISYS 8 2 1 Start the program The program can now be started from the start menu or via the links on the desktop The user name administrator is to be entered following installation No password is assumed simply click on OK ...

Page 36: ...ion Info Information regarding the DMMS the connected sen sors and the system Service 01 Name 16 Name 4 Register to set up the measuring channels configuration testscreen take sample curves System 3 Register for hardware configuration and test settings diagnosis memory 8 3 2 Symbol list Allows quick access to the following menu functions 1 New 5 Connect 9 Write 2 Open 6 Disconnect 10 Write all 3 S...

Page 37: ...ext file View Symbol list On and off Status list On and off Partitioning Partitioning of the selection and application windows DMMS Connect Establish connection between DIGISYS and PC Disconnect Disconnect connection between DIGISYS and PC Read all All data is read from the DIGISYS Read Read off the configuration from the DIGISYS Write all All data is loaded into the DIGISYS Write The configuratio...

Page 38: ... Determine user level and establish passwords for program start Other Seperation tags csv Tags for table values in csv text file for record take sample Common separation tags are commas or semicolons Activate Profibus License code for activating PROFIBUS User levels 1 Observer 2 User 3 Service personnel 4 Planning engineer 5 Administrator Privileges User level 1 2 3 4 5 View configuration X X X X ...

Page 39: ...munication cable and the serial interface COM port of the PC Click menu connect or When connection has been established read the configuration DMMS by clicking on yes 8 4 2 Menu write Modifications to the configuration only become effective if they are written in the DIGISYS evaluation and transmission module Click menu write or Confirm the writing by clicking on yes ...

Page 40: ...g the sliding regulators The back up measured values serve simulation of the measured values and are issued in place of the measured value by pressing the manual key The manual value is independent from the measured value Manual automatic switching Click field manual auto Confirm message with yes As an option the material temperature C can also be displayed For batch measurements the represented m...

Page 41: ... System ID Identification SV Software version HV Hardware version Date Program date SN Serial number Sensor info All recognised sensors 1 16 Addr Sensor bus address SN Serial number HV Hardware version SV Software version DT Date factory calibration System Storage of system specific information The entries have no influence on the measurements ...

Page 42: ... selected and then the required register Configuration test screen taking a sample or curves 8 7 1 Configuration Moisture Channel name Clear text description which is then displayed in the moisture screen Measuring mode Select a measuring mode in the selection window Sensor address Addresses which have been recognised upon activation of the equip ment and have not been allocated to other channels ...

Page 43: ...witching with fine batching Measuring range Range for the issue of measured values and display in whole percent units Lower threshold upper threshold The thresholds concern the working range of the mean value calcula tor A stray value or an interruption in the material flow is therefore not included in the mean value In the MW continuous measuring mode this halt function can be deactivated as requ...

Page 44: ...or Issue of manual value No measurement simulation of measured value only Batch cross sections Allows weighted mean value calculation as well as a curve switching with fine batching Coarse flow fine flow No curve switching Fine flow 0 Discontinuation of the measurement with fine signal only the coarse flow is measured Coarse flow fine flow Curve switching with fine batching the fine flow delivers ...

Page 45: ...ing procedure Start signal Level H the fine signal is present during the fine batching procedure Level L the fine signal is not present during the fine batching procedure Analogue output A measured value is transferred via an analogue output 0 10V or 4 20mA to another system Moisture output analogue output number for moisture measuring value If an error occurs behaviour of the output with the occu...

Page 46: ...time are also then extended 0 255 0 ADW rate Setting AD conversion sensor For test purposes only do not modify 0 255 10 Temperature gradient The measured value of certain materials is temperature dependent An entry in measured parts per Kelvin C can compensate for this 127 128 T K 0 T K Peak time Peak value within the peak time during measuring mode MW continuous i e for interfering air bubbles in...

Page 47: ...atus gu limit value below go limit value above vz delay time running kb curve B active fine curve MW median value calculation running Measured values Parts measuring parts offset moisture value of the sensor above the current calibrationcurve C material temperature Info Addr sensor bus address SN sensor serial number Channel display measuring channel status The channel condition green or error mes...

Page 48: ...tch measuring mode Continuous recording The recording is stopped or started immediately Joining the points The measuring points in the graph are connected with lines Deleting The recording is deleted via an additional confirmation Selecting signals Using the switches for parts moisture temperature and output the repre sentation of the signals in the graph can be switched on and off When creating t...

Page 49: ...ause allow a long term recording of the measured values in a text file optionally with date and time A window featuring save file as opens so that a file name can be desig nated The data can be evaluated with another program e g with MS EXCEL Cycle s The recording cycle can be set between 0 1 and 600 seconds The shorter the cycle time the more accurate the measurement result Excel representation E...

Page 50: ...terials can be deposited in each measuring channel Every material name represents its own set of curves The materials can be administered via the switch Set new material Determine the name create a new curve set with default values and open Change the material description Only the material name is changed Delete the material Delete material name and curve set Copy the material Copy curve set into ...

Page 51: ...n be selected depending on the configuration Arrow keys Graphic display area y x Set scaling of the y axis automatically to 1 100 of the x axis Curve type 2 10 points Evaluation of the samples is resulted on graph paper or via a table calculation system e g MS EXCEL 2 data points straight or several data points can then be entered The point list of the curve can be adminis trated via the switch ...

Page 52: ...c Shift curve Shift the curve by 0 5 F Small deviations in the measurement can thus be corrected quickly and efficiently then adopt curve Copy curve Insert curve Copying the curve into intermediate storage and inserting the curve from intermediate storage allows simple transferral of a curve into another measuring channel Curve type polynomial The mathematic correlation between measured parts and ...

Page 53: ...e Copying the curve into intermediate storage and inserting the curve from intermediate storage allows simple transferral of a curve into another measuring channel Polynomial as character string with MS EXCEL Process step Command entry Create and mark table with measurement parts and la boratory samples Insert diagram point xy Mark data set in the diagram Mark in the data stream diagram diagram in...

Page 54: ... value can be entered for each measurement channel In the auto operating mode the measured value is transmitted to the overriding system and a fixed value in the manual operating mode simulation Following activation the manual value is transmitted until a measured value has been obtained WAGO Number of individual WAGO I O modules The parameters are factory set and are only adjusted for extensions ...

Page 55: ...e after 0 1 5s Digital output Error signal through digital output 8 8 2 External material switching through digitalinputs A maximum of 16 materials can be switched within a channel through the DIGISYS Only the first 8 channels can be switched externally Prerequisite The materials must already be set A sufficient number of digital inputs must be available WAGO 750 402 Once Profibus has been activat...

Page 56: ...MS DIGISYS The assignment of the digital inputs is shown on the monitor Binary code representation n channel 1 0 0 V 1 24 V Assignment Digital inputs Material number Mn 8 Mn 4 Mn 2 Mn 1 0 0 0 0 M00 0 0 0 1 M01 0 0 1 0 M02 0 0 1 1 M03 0 1 0 0 M04 0 1 0 1 M05 0 1 1 0 M06 0 1 1 1 M07 ...

Page 57: ...puts 4 to 5 are assigned to switch between the materials M00 and M02 from channel 2 Channel 1 Assignment of the digital inputs Material number Material Number of materials M00 Tea 6 M01 Wood chips M02 Cat food M03 Wheat M04 Barley M05 Oats Channel 2 Material number Material Number of materials M00 Rye 3 M01 Corn M02 Soy A WAGO 750 402 Settings example Inputs 1 and 2 are live See red cable guide wi...

Page 58: ...etries without responses LoopCnt number of attempts Read read statistics Reset reset statistics Status show channel status 8 8 5 Memory Read assignment display storage assignment NVRAM Default SysInfo only resets the system settings to the factory values The configuration and curve memory are not deleted Default NVRAM resets the entire memory of the evaluation and transfer module to the factoryval...

Page 59: ...asuring sensor and slide The moisture measuring sensor is integrated into the slide They are on top on the sand and both slides over through the sand The moisture measuring sensor has the bus address 1 The 1 st analogue output should be 4 20mA for a measuring range from 0 20 moisture 9 2 Commissioning 1 At first you have to plug the delivered WAGO Service Cable 750 920 or WAGO USB Service Cable 75...

Page 60: ...e for measuring value display and issue is 0 20 mois ture 10 The thresholds must be within the measuring range 11 The moisture value is at analogue output 1 without error signali sation 12 Switch to Take Sample register card and click the continuous box to enter a tick symbol The measured values of the material flow are recorded Simultaneously take material samples from the discharge points and as...

Page 61: ...wMaterial and designate a material name 17 Select Type 2 10 points 18 Type in the values 475 and 5 0 into the fields Digits M carry out Add Point 19 Type in the values 528 and 7 3 into the fields Digits and M carry out Add Point You can add from 2 to 10 points to one curve 20 Select the old points and carry out Delete Point respectively The new curve will also be displayed in the graphic 21 If eve...

Page 62: ...n a separate window in clear text and must be confirmed 10 1 2 DMMS error signalisation Errors which are recognised by the DIGISYS evaluation and transmission module are displayed via a flash ing code error code See evaluation and transmission module LED signalisation These errors are also listed in a separate window DMMS error signalisation The window then remains in the foreground and can be min...

Page 63: ... LD 2 x 2 x 0 22 DIGISYS evaluation and transmission module basic equipment USB RS232 serial adapter Communication cable WAGO 750 920 USB service cable 750 923 000 001 Options 4 channel digital input terminal 3ms WAGO 750 402 2 channel analogue output terminal 0 10V WAGO 750 550 2 channel analogue output terminal 4 20mA WAGO 750 554 Relay output terminal 250 V AC 30V DC 2A AC DC WAGO 750 513 4 cha...

Page 64: ... Before connecting the cable to the computer install the USB adapter driver 12 1 1 Install the driver software The driver software can be found on the Wago DVD Place the DVD in the DVD drive The installation software usually starts up automatically If the installation software does not startautomatically Start the driver installation by double clicking the file Select the installation language ...

Page 65: ...er Click on downloads in the pulldown menu service Click on the button automation in the sub menu downloads Read the general terms and conditions To install the necessary driver the general terms and conditions must be accepted Click the button I agree to the general terms and conditions ...

Page 66: ...Operating Instructions DMMS_DIGISYS ACO Automation Components 66 Connect the USB adapter Select driver no 759 923 Save the ZIP file to the hard drive Expand the Zip file Double click setup exe ...

Page 67: ...elect the installation path If a warning shows up regarding the software installation click on the button continue installation or install now If the installation was successful a notice will be shown Complete the Installation with OK Click on OK The software installation has been completed ...

Page 68: ...led connect the USB adapter Connect the USB adapter to an available USB slot on the computer The computer s hardware assistant will open Determine the type of connection with Windows Update Select the field yes only once Click on the continue button Insert the CD Select the field install software automatiically Click on the continue button The hardware is located ...

Page 69: ... on the button continue installation or install now After a few seconds the driver is installed and the USB adapter is ready to use After the installation of the driver the next available virtual COM port is reserved for the cable The reserved COM port in the control panel of the computer can be found in start settings control panel system hardware device manager connections The COM port is releas...

Page 70: ...ed Uninstall the driver software Open the device manager Path start settings control panel system hardware device manager connections Select the COM port of the USB adapter Switch to the driver registration card Click on the button uninstall and uninstall the driver Then reinstall the driver software as described in this sub chapter 12 1 4 Technical data See the manufacturer s data sheet in the bo...

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